Perforated foams

ABSTRACT

Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substiantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

This application is a 371 of PCT/US99/11754 filed May 27, 1999 whichclaims benefit of No. 60/100,699 filed Sep. 17, 1998.

The present invention relates to foams in general, and moreparticularly, to thermoplastic polymer foams useful in sound management.

In the construction industry, it is well known to use panels aspartition walls in order to subdivide the building area into separateareas such as rooms and offices. Usually they consist of an insulatingmineral fiber core, and two outer facing layers encompassing the core,and an air gap or hollow space. The insulating materials such as mineralfibers are arranged between the facing layers in such a manner so as toprovide thermal and/or acoustic insulation. However, a majordisadvantage of such partitions or panels having mineral fiber cores isthe lack of mechanical strength of such fibers which therefore require acostly supporting structure or densification. In addition, mineral fiberproducts are unpleasant to handle causing skin irritation and possiblypresenting a health hazard.

Foams have also been utilized as sound insulating materials. Forexample, WO 95/14136 discloses multilayered insulating panels orelements comprising, in a preferred embodiment, (a) two outer facinglayers, and (b) a soft synthetic core material which is a single,continuous, soft, synthetic, closed-cell foam core layer having hollowprofiles. The core material is arranged in intimate contact with bothouter layers through contact points in alternate patterns, therebyproviding gaps between the core layer and the opposing outer layer.However, the closed-cell foam utilized as the core layer in WO 95/14136provides less than satisfactory sound insulation for demandingapplications.

Although not wishing to be bound by any particular theory, theusefulness of a particular polymeric foam in sound management (forexample, sound absorption and sound insulation) it is believed by theinventor of the present application to be dependent upon the foam havingone or more of the following properties: 1) average cell size greaterthan about 2 mm; 2) substantially open-cell structure and 3) relativelylarge pore connecting the cells. In order that the foam be acousticallyactive, the foam should possess a substantially open-cell structure anda relatively low airflow resistivity. One or more of these sameproperties also are believed to contribute to the usefulness of a foamfor filtering and fluid absorption.

Certain large pore, open-celled foams are known. However, they alsopossess one or more drawbacks. For example, thermoset resins such asmelamine and semi-rigid polyurethane can be used to prepare foams whichdisplay the desired large pore, open-celled structure believed to berequired for sound management. However, thermoset resins are notrecyclable, are costly to manufacture, and are unsuitable for use inhumid or wet environments due to their hydrolytic instability.Thermoplastic polymer foams are generally inexpensive to manufacture bya convenient extrusion process, are recyclable, and exhibit hydrolyticstability, and therefore offer an advantage over thermoset resins.However it is difficult to achieve a large-pore thermoplastic foam withan open-cell structure by a convenient direct extrusion process. Thesedifficulties exist because cell opening and foam expansion contradicteach other. That is, the growing cells within the foam must remain dosedin order to grow, but developing a large pore requires that a hole mustdevelop on the cell wall shortly before the end of expansion.

In addition, although certain thermoplastic polymer foams are reportedto be useful in sound management, it is questionable whether their soundmanagement performance is satisfactory for a demanding application.(See, for example, DE 3,626,349 to Dynamit Nobel A G, published Feb. 11,1988, DE 3,626,350 to Dynamit Nobel A G, published Feb. 11, 1988, and WO95/14136, to Dow Chemical, published May 26, 1995).

Therefore, there remains a need in the art for foams which provide sounddeadening properties satisfactory for demanding applications, which havemechanical strength, which are economical to manufacture, and which arehydrolytically stable.

That need is met by the present invention. Thus, the present inventionprovides thermoplastic polymer foams having sound deadening propertiessatisfactory for demanding applications, which have mechanical strength,which are economical to manufacture, and which are hydrolyticallystable.

Thus, in one embodiment of the present invention, there is providedthermoplastic polymer foams having an average cell size greater thanabout 4 mm are provided.

In another embodiment, there is provided thermoplastic polymer foamshaving an average cell size of greater than about 2 mm wherein greaterthan about 50 percent of the cells have been opened by mechanical meansare provided.

In yet another embodiment, the present invention provides athermoplastic polymer foam having an airflow resistivity of less thanabout 800,000 Rayls/m and an average cell size of greater than about 2mm, and wherein greater than about 50 percent of the cells have beenopened by mechanical means.

In yet still another embodiment, the present invention providesprocesses for preparing thermoplastic polymer foam structures having anaverage cell size of greater than about 2 mm, and wherein greater thanabout 50 percent of the cells have been opened by mechanical means.

The foams of the present invention are particularly useful for soundabsorption, sound insulation, fluid absorption, filtering, cushionpackaging and other applications requiring one or more of the followingproperties: sound deadening or sound damping properties, mechanicalstrength, economical manufacture, and hydrolytically stability.

FIG. 1 depicts process for preparing a foam of the present inventionwherein closed-cells within a foam are being opened by perforation.

FIG. 2 depicts a process for preparing a foam of the present inventionwherein elongated closed-cells within a foam are being opened byperforation.

FIG. 3 depicts a process for preparing a foam of the present inventionwherein elongated closed-cells within a foam are being opened byperforation at an oblique angle.

FIG. 4 depicts a process for preparing a foam of the present inventionwherein closed-cells within a foam are opened by compression followed byperforation.

FIG. 5 depicts a sound absorption curve of a foam of the presentinvention.

FIG. 6 depicts a sound absorption curve of a foam of the presentinvention.

FIG. 7 depicts a sound absorption curve of a foam of the presentinvention.

FIG. 8 depicts a sound absorption curve of a foam of the presentinvention.

FIG. 9 depicts a profile of a foam of the present invention, whichprofile is designated I.

FIG. 10 depicts a profile of a foam of the present invention, whichprofile is designated U.

FIG. 11 depicts a profile of a foam of the present invention, whichprofile is designated W.

The present invention provides thermoplastic polymer foams having sounddeadening properties satisfactory for demanding applications, which havemechanical strength, are economical to manufacture, and which arehydrolytically stable. The foams of the present invention exhibitproperties or combinations of properties which have heretofore beendifficult, if not impossible, to achieve. Thus, the foams of the presentinvention exhibit one or more of the following properties: 1) averagecell size greater than about 2 mm; 2) substantially open-cell structureand 3) relatively large pore connecting the cells.

In order that the foam be acoustically active, the foam should possess asubstantially open-cells structure and a relatively low airflowresistivity. According to the present invention, foams withsubstantially open-cell structure and relatively low airflow resistivityare prepared by mechanically opening a foam having an average cell sizegreater than about 2 mm. In most cases, such mechanical opening createsrelatively large pores connecting the cells.

Thermoplastic resins suitable for use in the present invention includeall types of thermoplastic polymers and blends that are foamable byextrusion processes. Examples of thermoplastic polymer resins suitablefor the present invention include, but are not limited to, polystyrenesand polyolefin resins, including polyethylene resins, polypropyleneresins, as well as blends of ethylene-styrene interpolymer (ESI) resinswith polyolefin resins, such as blends of polyethylene and ESI orpolypropylene and ESI, with polyethylene resins, copolymers ofpolyethylene resins, and blends of polyethylene resins being preferred.Examples of such resins are low density polyethylene resins, such asthose having a melt index of about 0.4 dg/minute and a density of 0.922g/cm³.

Preferred themoplastic resins also include olefinic polymers. Preferredolefinic polymers include ethylenic polymers, copolymers, and blendsthereof.

The afore-mentioned ethylene-styrene interpolymer is a substantiallyrandom interpolymer comprising in polymerized form i) one or moreα-olefin monomers and ii) one or more vinyl or vinylidene aromaticmonomers and/or one or more sterically hindered aliphatic orcycloaliphatic vinyl or vinylidene monomers, and optionally iii) otherpolymerizable ethylenically unsaturated monomer(s).

The term “interpolymer” is used herein to indicate a polymer wherein atleast two different monomers are polymerized to make the interpolymer.

The term “substantially random” is the substantially random interpolymerresulting from polymerizing i) one or more α-olefin monomers and ii) oneor more vinyl or vinylidene aromatic monomers and/or one or moresterically hindered aliphatic or cycloaliphatic vinyl or vinylidenemonomers, and optionally iii) other polymerizable ethylenicallyunsaturated monomer(s) as used herein generally means that thedistribution of the monomers of said interpolymer can be described bythe Bernoulli statistical model or by a first or second order Markovianstatistical model, as described by J. C. Randall in POLYMER SEQUENCEDETERMINATION, Carbon-13 NMR Method, Academic Press New York, 1977, pp.71-78. Preferably, the substantially random interpolymer resulting frompolymerizing one or more α-olefin monomers and one or more vinyl orvinylidene aromatic monomers, and optionally other polymerizableethylenically unsaturated monomer(s), does not contain more than 15percent of the total amount of vinyl or vinylidene aromatic monomer inblocks of vinyl or vinylidene aromatic monomer of more than 3 units.More preferably, the interpolymer is not characterized by a high degreeof either isotacticity or syndiotacticity. This means that in thecarbon-13 NMR spectrum of the substantially random interpolymer the peakareas corresponding to the main chain methylene and methine carbonsrepresenting either meso diad sequences or racemic diad sequences shouldnot exceed 75 percent of the total peak area of the main chain methyleneand methine carbons. By the subsequently used term “substantially randominterpolymer” is meant a substantially random interpolymer produced fromthe above-mentioned monomers.

Suitable α-olefin monomers which are useful for preparing thesubstantially random interpolymer include, for example, α-olefinmonomers containing from 2 to 20, preferably from 2 to 12, morepreferably from 2 to 8 carbon atoms. Particularly suitable are ethylene,propylene, butene-1,4-methyl-1-pentene, hexene-1 or octene-1 or ethylenein combination with one or more of propylene,butene-1,4-methyl-1-pentene, hexene-1 or octene-1. Most preferred areethylene or a combination of ethylene with C₃₋₈-α-olefins. Theseα-olefins do not contain an aromatic moiety.

Other optional polymerizable ethylenically unsaturated monomer(s)include strained ring olefins such as norbornene and C₁₋₁₀ alkyl orC₆₋₁₀ aryl substituted norbornenes, with an exemplary interpolymer beingethylene/styrene/norbornene.

Suitable vinyl or vinylidene aromatic monomers which can be employed toprepare the substantially random interpolymer include, for example,those represented by the following Formula I

wherein R¹ is selected from radicals consisting of hydrogen and alkyradicals containing from 1 to 4 carbon atoms, preferably hydrogen ormethyl; each R² is independently selected from the group of radicalsconsisting of hydrogen and alkyl radicals containing from 1 to 4 carbonatoms, preferably hydrogen or methyl; Ar is a phenyl group or a phenylgroup substituted with from 1 to 5 substituents selected from the groupconsisting of halo, C₁₋₄-alkyl, and C₁₋₄-haloalkyl; and n has a valuefrom zero to 4, preferably from zero to 2, most preferably zero.Particularly suitable such monomers include styrene and lower alkyl- orhalogen-substituted derivatives thereof. Preferred monomers includestyrene, α-methyl styrene, the lower alkyl-(C₁-C₄) or phenyl-ringsubstituted derivatives of styrene, such as for example, ortho-, meta-,and para-methylstyrene, t-butyl styrene, the ring halogenated styrenes,such as chlorostyrene, para-vinyl toluene or mixtures thereof. A morepreferred aromatic monovinyl monomer is styrene.

The most preferred substantially random interpolymers are interpolymersof ethylene and styrene and interpolymers of ethylene, styrene and atleast one α-olefin containing from 3 to 8 carbon atoms.

The substantially random interpolymers usually contain from 0.5 to 65,preferably from 1 to 55, more preferably from 2 to 50 mole percent of atleast one vinyl or vinylidene aromatic monomer and/or stericallyhindered aliphatic or cycloaliphatic vinyl or vinylidene monomer andfrom 35 to 99.5, preferably from 45 to 99, more preferably from 50 to 98mole percent of at least one aliphatic α-olefin having from 2 to 20carbon atoms. These interpolymers can be prepared according toWO98/10014 incorporated herein by reference.

Optionally, a nucleating agent may be added to the foamable blend. Theamount of nucleating agent employed to prepare the foams of the presentinvention will vary according to the desired cell size, the foamingtemperature, and the composition of the nucleating agent. For example,when a large foam size is desired, little or no nucleating agent shouldbe used. Useful nucleating agents include calcium carbonate, bariumstearate, calcium stearate, talc, clay, titanium dioxide, silica, bariumstearate, diatomaceous earth, mixtures of citric acid and sodiumbicarbonate. When utilized, the amount of nucleating agent employed mayrange from 0.01 to 5 parts by weight per hundred parts by weight of thepolymer resin blend (pph).

Blowing agents useful in making the present foam include all types ofblowing agents known in the art; physical and chemical blowing agentsand mixtures thereof, including inorganic blowing agents, organicblowing agents, and chemical blowing agents. Suitable inorganic blowingagents include carbon dioxide, nitrogen, argon, water, air, and helium.Organic blowing agents include aliphatic hydrocarbons having 1-6 carbonatoms, aliphatic alcohols having 1-3 carbon atoms, and fully andpartially halogenated aliphatic hydrocarbons having 1-4 carbon atoms.Aliphatic hydrocarbons include methane, ethane, propane, n-butane,isobutane, n-pentane, isopentane, and neopentane. Aliphatic alcoholsinclude methanol, ethanol, n-propanol, and isopropanol. Fully andpartially halogenated aliphatic hydrocarbons include chlorocarbons,fluorocarbons, and chlorofluorocarbons. Chlorocarbons for use in thisinvention include methyl chloride, methylene chloride, ethyl chloride,and 1,1,1-trichloroethane. Fluorocarbons for use in this inventioninclude methyl fluoride, methylene fluoride, ethyl fluoride,1,1-difluoroethane (HFC-152a), 1,1,1-trifluoroethane (HGC-143a),1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane(HFC-134), pentafluoroethane, perfluoroethane, 2,2difluoropropane,1,1,1-trifluoropropane, and 1,1,1,3,3-pentafluoropropane. Partiallyhydrogenated chlorofluorocarbons for use in this invention includechlorodifluoromethane (HCFC-22), 1,1-dichloro-1-fluoroethane(HCFC-141b), 1-chloro-1,1-difluoroethane (HCFC-142b),1,1-dichloro-2,2,2-trifluoroethane (HCFC-123), and1-chloro-1,2,2,2-tetrafluoroethane (HCFC-124). Fully halogenatedchlorofluorocarbons may also be used but are not preferred forenvironmental reasons. Chemical blowing agents for use in this inventioninclude azodicarbonamide, azodiisobutyro-nitrile,benzenesulfonylhydrazide, 4,4-oxybenzene sulfonyl-semicarbazide,p-toluene sulfonyl semicarbazide,N,N═-dimethyl-N,N═-dinitrosoterephthalamide, and trihydrazine triazine,sodium bicarbonate, mixtures of sodium bicarbonate and citric acid.Mixtures of all these blowing agents are also contemplated within thescope of this invention. Preferred blowing agents for the extrusionprocess and batch process for making moldable beads are physical blowingagents, with volatile organic blowing agents being preferred, with lowhydrocarbons (for example, propane and butane) being most preferred.Preferred blowing agents for cross-linked foam processes aredecomposable blowing agents and nitrogen,

The amount of blowing agent incorporated into the polymer melt materialto make a foaming gel is varied as required to achieve a predetermineddensity.

The foams of the present invention optionally further comprise aninfrared absorber (transmission blocker) such as carbon black, graphite,or titanium dioxide, to enhance thermal insulating capability. Whenutilized, the infrared absorber may comprise between 1.0 and 25 weightpercent and preferably between 2.0 and 10.0 weight percent, based uponthe weight of the polymer blend in the foam. The carbon black may be ofany type known in the art such as furnace black, thermal black,acetylene black, and channel black.

It is preferred that the foams of the present invention exhibitdimensional stability. A stability control agent may be especiallydesirable in producing thick (that is, greater than 4 mm) sheet andplank products (thicker than about 12 mm) of substantially closed-cellstructure from the foregoing foams. In contrast, an additional stabilitycontrol agent is probably not necessary or desirable when formingsubstantially open-celled foams.

Dimensional stability is measured by taking the foam volume during agingas a percentage of the initial volume of the foam, measured within 30seconds after foam expansion. Using this definition, a foam whichrecovers 80 percent or more of the initial volume within a month istolerable, whereas a foam which recovers 85 percent or more ispreferred, and a foam which recovers 90 percent or more is especiallypreferred. Volume is measured by a suitable method such as cubicdisplacement of water.

Preferred stability control agents include amides and esters of C₁₀₋₂₄fatty acids. Such agents are taught in U.S. Pat. Nos. 3,644,230 and4,214,054. Most preferred agents include stearyl stearamide, glycerolmonostearate, glycerol monobenenate, and sorbitol monostearate.Typically, such stability control agents are employed in an amountranging from 0.1 to 10 parts per hundred parts of the polymer.

Various additives may also be incorporated in the foams such asinorganic fillers, pigments, antioxidants, acid scavengers, ultravioletabsorbers, flame retardants, processing aids, or extrusion aids.

The polymer foams of the present invention may be prepared by techniquesand procedures well known to one of ordinary skill in the art andinclude extrusion processes as well as batch processes using adecomposable blowing agent and cross-linking, with extrusion processesbeing preferred.

In an extrusion process, the cell-size is affected by several parametersthat include the type and level of blowing agent, the polymer type, thegeometry of the die orifice, the shear rate at the die, the level ofnucleating agent, the use of a cell enlarging agent, and the foamingtemperature. In order to make the cell size large, the cell nucleatingagent is normally not added. Instead, a cell enlarging agent may beadded. Among the rest of the parameters, the type and level of blowingagent have the greatest effect on the cell size. Ordinarily, blowingagents having a relatively high solubility and a small molecular size ata relatively low level provide a large cell size. Examples of suchblowing agents include propane, n-butane, isobutane, n-pentane, methylchloride, methylene chloride, ethyl chloride, methanol, ethanol,dimethyl ether, water, and a mixed blowing agent containing one or moreof these blowing agents. Branched ethylenic polymer resins prepared bythe high-pressure free-radical method tend to provide large cells whenexpanded with these blowing agents. The cell size enlarging additivesare, in general, those compounds that are used in plasticizing polymerresins. Examples of cell size enlargers include waxy materials having arelatively low melting point as are described in U.S. Pat. No. 4,229,396, and non-waxy low molecular weight compounds as are disclosed inU.S. Pat. No. 5,489,407. In addition, a relatively low shear rate at thedie orifice results in a large cell size.

The polymer foams of the present invention may be cross-linked ornon-cross-linked. Processes for making polymer foam structures andprocessing them are taught in C. P. Park, Polyolefin Foam, Chapter 9,Handbook of Polymer Foams and Technology, edited by D. Klempner and K.C. Frisch, Hanser Publishers, Munich, Vienna, New York Bareelona (1991).

Non-crosslinked foams of the present invention may be made by aconventional extrusion foaming process. The foam structure is generallyprepared by heating a thermoplastic polymer resin (that is, polymermaterial) to form a plasticized or melt polymer material, incorporatingtherein a blowing agent to form a foamable gel, and extruding the gelthrough a die to form the foam product. Prior to mixing with the blowingagent, the polymer material is heated to a temperature at or above itsglass transition temperature or melting point. The blowing agent may beincorporated or mixed into the melt polymer material by any means knownin the art, such as with an extruder, mixer, blender, or the like. Theblowing agent is mixed with the melt polymer material at an elevatedpressure sufficient to prevent substantial expansion of the melt polymermaterial and to disperse the blowing agent homogeneously therein.Optionally, a nucleator may be blended in the polymer melt or dryblended with the polymer material prior to plasticizing or melting. Thefoamable gel is typically cooled to a lower temperature to optimizephysical characteristics of the foam structure. The gel is then extrudedor conveyed through a die of desired shape to a zone of reduced or lowerpressure to form the foam structure. The zone of lower pressure is at apressure lower than that in which the foamable gel is maintained priorto extrusion through the die. The lower pressure may be superatmosphericor subatmospheric (vacuum), but is preferably at an atmospheric level.

Non-crosslinked foams of the present invention may be formed in acoalesced strand form by extrusion of the thermoplastic polymer resin(that is, polymer material) through a multi-orifice die. The orificesare arranged so that contact between adjacent streams of the moltenextrudate occurs during the foaming process and the contacting surfacesadhere to one another with sufficient adhesion to result in a unitaryfoam structure. The streams of molten extrudate exiting the die take theform of strands or profiles, which desirably foam, coalesce, and adhereto one another to form a unitary structure. Desirably, the coalescedindividual strands or profiles should remain adhered in a unitarystructure to prevent strand delamination under stresses encountered inpreparing, shaping, and using the foam. Apparatuses and method forproducing foam structures in coalesced strand form are taught in U.S.Pat. Nos. 3,573,152 and 4,324,720.

The present foam structure may also be formed into non-cross-linked foambeads suitable for molding into articles. The foam beads may be preparedby an extrusion process or a batch process. In the extrusion process,the foam strands coming out of a multi-hole die attached to aconventional foam extrusion apparatus are granulated to form foam beads.In a batch process, discrete resin particles such as granulated resinpellets are: suspended in a liquid medium in which they aresubstantially insoluble such as water; impregnated with a blowing agentby introducing the blowing agent into the liquid medium at an elevatedpressure and temperature in an autoclave or other pressure vessel; andrapidly discharged into the atmosphere or a region of reduced pressureto expand to form the foam beads. This process is taught in U.S. Pat.Nos. 4,379,859 and 4,464,484.

Cross-linked foams of the present invention may be prepared by eitherthe cross-linked foam process employing a decomposable blowing agent orby conventional extrusion processes.

When utilizing the cross-linked foam process employing a decomposableblowing agent, crosslinked foams of the present invention may beprepared by blending and heating the thermoplastic polymer resin (thatis, polymer material) with a decomposable chemical blowing agent to forma foamable plasticized or melt polymer material, extruding the foamablemelt polymer material through a die, inducing cross-linking in the meltpolymer material, and exposing the melt polymer material to an elevatedtemperature to release the blowing agent to form the foam structure. Thepolymer material and the chemical blowing agent may be mixed and themelt blended by any means known in the art such as with an extruder,mixer, blender, or the like. The chemical blowing agent is preferablydry-blended with the polymer material prior to heating the polymermaterial to a melt form, but may also be added when the polymer materialis in melt phase. Cross-linking may be induced by addition of across-linking agent or by radiation. Induction of cross-linking andexposure to an elevated temperature to effect foaming or expansion mayoccur simultaneously or sequentially. If a cross-linking agent is used,it is incorporated into the polymer material in the same manner as thechemical blowing agent. Further, if a cross-linking agent is used, thefoamable melt polymer material is heated or exposed to a temperature ofpreferably less than 150° C. to prevent decomposition of thecross-linking agent or the blowing agent and to prevent prematurecross-linking. If radiation cross-linking is used, the foamable meltpolymer material is heated or exposed to a temperature of preferablyless than 160° C. to prevent decomposition of the blowing agent. Thefoamable melt polymer is extruded or conveyed through a die of desiredshape to form a foamable structure. The foamable structure is thencross-linked and expanded at an elevated or high temperature (typically,150° C. to 250° C.) such as in an oven to form a foam structure. Whenradiation cross-linking is used, the foamable structure is irradiated tocross-link the polymer material, which is then expanded at the elevatedtemperature as described above. The structure can advantageously be madein sheet or thin plank form according to the above process using eithercross-linking agents or radiation.

In addition to use of a cross-linking agent or radiation in thecross-linked foam process employing a decomposable blowing agent,cross-linking may also be accomplished by means of silane cross-linkingas described in C. P. Park, Supra, Chapter 9.

Cross-linked foams of the present invention may also be made into acontinuous plank structure by an extrusion process utilizing a long-landdie as described in GB 2,145,961A. In that process, the polymer,decomposable blowing agent, and cross-linking agent are mixed in anextruder; the mixture is heated to permit the polymer to cross-link andthe blowing agent to decompose in a long-land die; and foam structure isshaped and conducted away from the die, with the foam structure and thedie contact being lubricated by a proper lubrication material.

Cross-linked foams of the present invention may also be formed intocross-linked foam beads suitable for molding into articles. To make thefoam beads, discrete resin particles such as granulated resin pelletsare: suspended in a liquid medium in which they are substantiallyinsoluble such as water; impregnated with a cross-linking agent and ablowing agent at an elevated pressure and temperature in an autoclave orother pressure vessel; and rapidly discharged into the atmosphere or aregion of reduced pressure to expand to form the foam beads. In anotherversion of the process, the polymer beads are impregnated with blowingagent cooled down, discharged from the vessel, and then expanded byheating or with steam. In a derivative of the above process, styrenemonomer may be impregnated into the suspended pellets along with thecross-linking agent to form a graft interpolymer with the polymermaterial. Blowing agent may be impregnated into the resin pellets whilein suspension, or alternatively, in a non-hydrous state. The expandablebeads are then expanded by heating with steam and molded by aconventional molding method for the expandable polystyrene foam beads.

The foam beads may then be molded by any means known in the art, such ascharging the foam beads to the mold, compressing the mold to compressthe beads, and heating the beads such as with steam to effect coalescingand welding of the beads to form the article. Optionally, the beads maybe pre-heated with air or other blowing agent prior to charging to themold. Excellent teachings of the above processes and molding methods arefound in C. P. Park, Supra, pp. 227-233, U.S. Pat. Nos. 3,886,100;3,959,189; 4,168,353, and 4,429,059. The foam beads can also be preparedby preparing a mixture of polymer, cross-linking agent, and decomposablemixtures in a suitable mixing device or extruder and forming the mixtureinto pellets, and heating the pellets to cross-link and expand.

Another process for making cross-linked foam beads suitable for moldinginto articles to melt the polymer material and mix it with a physicalblowing agent in a conventional foam extrusion apparatus to form anessentially continuous foam strand. The foam strand is granulated orpelletized to form foam beads. The foam beads are then cross-linked byradiation. The cross-linked foam beads may then be coalesced and moldedto form various articles as described above for the other foam beadprocess. Additional teachings of this process are found in U.S. Pat. No.3,616,365 and C. P. Park, Supra, pp. 224-228.

In addition, silane cross-linking technology may be employed in theextrusion process. Teachings of this process are found in C. P. Park,Supra, Chapter 9 and in U.S. Pat. No. 4,714,716. When silanecross-linking processes are utilized with conventional extrusionprocesses, a polymer is grafted with a vinyl functional silane or anazido functional silane and extruded to form foams. The extruded foamsare then exposed to warm humid air for the cross-linking to develop.

The cross-linked foams of the present invention may be made in bun stockform by mixing the polymer material, a cross-linking agent, and ablowing agent to form a slab, heating the mixture in a mold so thecross-linking agent can cross-link the polymer material and the blowingagent can decompose, and expanding the foam by release of pressure inthe mold. Optionally, the bun stock formed upon release of pressure maybe re-heated to effect further expansion.

Cross-linked polymer sheet is made by irradiating a polymer sheet with ahigh energy beam or by heating a polymer sheet containing a chemicalcross-linking agent. The cross-linked polymer sheet is cut into thedesired shapes and impregnated with nitrogen under high pressure and ata temperature above the softening point of the polymer. Releasing thepressure effects nucleation of bubbles and some expansion in the sheet.The sheet is reheated in a low pressure vessel under pressure above thesoftening point, and the pressure is released so that the foam canexpand.

Foams prepared by the above-methods exhibit densities of from 10 kg/m³to 300 kg/m³, with foams having densities of from 15 kg/m³ to 100 kg/m³being preferred, and foams having densities of from 15 kg/m³ to 60 kg/m³being particularly preferred. In addition, foams prepared by theabove-methods exhibit an average cell size of from 2 mm to 15 mm, withcell sizes of from 2 mm to 10 mm being preferred, from 3 mm to 10 mmbeing more preferred, and from 4 mm to 8 mm being particularlypreferred. In one preferred embodiment, the cellular thermoplasticpolymer foam has an average cell diameter greater than 4 mm. Inaddition, the foams prepared by the above-methods may be open or closedcelled.

Foams prepared according to the above-methods may be useful in soundmanagement without additional process steps. For example, foams preparedby the above-methods having an average cell size greater than about 4 mmmay exhibit a sufficiently low airflow resistivity to be suitable foruse as a sound absorption material irrespective of other propertieswhich the foam may possess and without the need for additional processsteps. Typically, for sound management end-uses, airflow resistivitiesof less than about 800,000 Rayls/m (that is, 800,000 Pa.s/m²) isdesirable, with less than 400,000 Rayls/m (that is, 400,000 Pa.s/m²),less than 100,000 Rayls/m (that is, 100,000 Pa.s/m²), and less than50,000 Rayls/m (that is, 50,000 Pa.s/m²) being increasingly moredesirable depending upon the end-use of the foam.

However, in the event that the base foams prepared by the above methodsdo not exhibit sufficient sound management properties, the addition orenhancement of properties such as 1) substantially open-cell structureand 2) relatively large pores connecting the cells, may be imparted tothe base foam by opening closed-cells within the base foam by mechanicalmeans.

As stated previously, in order that the foam be acoustically active, thefoam should possess a substantially open-cell structure and a relativelylow airflow resistivity. According to the present invention, foams withsubstantially open-cell structure and relatively low airflow resistivityare prepared by mechanically opening a foam having an average cell sizegreater than about 2 mm. In most cases, such mechanical opening createsrelatively large pores connecting the cells. For example, closed-cellswithin the foam may be opened by applying a means for openingclosed-cells in a cellular thermoplastic polymer foam to at least someportion of at least one surface of base thermoplastic polymer foam, suchapplication being sufficient to result in at least some portion ofclosed-cells within the base polymer foam being opened. The portion ofclosed-cells opened by the mechanical means will of course depend uponthe extent of the application of the means for opening the closed-cells.For example, if a smaller percentage of closed-cells are to be opened,the application of the means for opening will be applied to only aportion of the surface of the base foam and/or extend only partiallythrough the thickness of the base foam. However, if a larger percentageof closed-cells are to be opened, the application of the means foropening will be applied to more of the surface of the bass foam and/orextend farther into the thickness of the base foam.

The direction of the application of the means for opening closed-cellsis immaterial and may be performed either perpendicular to or with thedirection of extrusion and may be performed at any angle with respect tothe surface of the base foam.

The means for opening closed-cells may be any means sufficient to openclosed-cells, but will typically include perforation, slicing,compression, or combinations thereof. Typically, perforation comprisespuncturing the base foam with one or more pointed, sharp objects.Suitable pointed, sharp objects include needles, spikes, pins, or nails.In addition, perforation may comprise drilling, laser cutting, highpressure fluid cutting, air guns, or projectiles. FIG. 1 depicts across-section of a base foam 1 of the present invention comprised of amultiplicity of closed-cells 2, foam 1 being perforated with amultiplicity of pointed, sharp objects 3.

In addition, the base foam may be prepared to have elongated cells bypulling the foam strand during expansion. Such pulling results inelongated cells without changing or often, increasing the cell size inthe horizontal direction. Thus, pulling results in an increased averagecell size in the direction perpendicular to the vertical direction (EHaverage) and facilitates perforation. FIG. 2 depicts a cross-section ofa base foam 1 of the present invention comprised of a multiplicity ofclosed-cells which have been elongated in the direction of extrusion 4which have then been perforated with a multiplicity of pointed, sharpobjects 3. FIG. 3 depicts a cross section of a base foam 1 of thepresent invention comprised of a multiplicty of closed-cells which havebeen elongated in the direction of extrusion 4 which have then beenperforated with a multiplicity of pointed, sharp objects 3 at an obliqueangle.

Perforation of the base foam may be performed in any pattern, includingsquare patterns and triangular patterns. In addition, it is preferredthat the distance between perforations be on the order of the cell sizewithin the foam in order to perforate the majority of cells. Therefore,when it is desired that a majority of cells be perforated, it ispreferred that the perforation is performed in a manner which results inthe perforations being spaced one from another at distances which are nogreater than two times the average diameter of the cells within the basefoam, preferably no greater than 1.5 times, more preferably equal to theaverage diameter of the cells within the base foam, and most preferably,less than the average diameter of the cells within the base foam.Although the choice of a particular diameter of the sharp, pointedobject with which to perforate the base foam is dependent upon manyfactors, including average cell size, intended spacing of perforations,pointed, sharp objects useful in the preparation of certain foams of thepresent invention will typically have diameters of from 1 mm to 4 mm.

Slicing may be performed by any means sufficient to slice through atleast a portion of foam, and includes knives, and saws. Opening cells ofthe base foam by slicing necessarily only opens those cells at the cutsurface, leaving the cells in the interior of the foam unchanged.Therefore, slicing does not reduce the airflow resistivity throughoutthe thickness of the foam. However, opening surface cells by slicing maybe sufficient for certain sound management applications, especially ifthe cell size is sufficiently large and/or the remaining uncut foam issufficiently thin. Although not wishing to be bound by any particulartheory, it is believed by the inventor of the present application thatfor effective sound absorption, it is not required that there be lowairflow resistivity throughout the thickness of the foam. This isbecause sound is a compression wave of air which propagates by movementof air molecules in an oscillatory manner (that is, the air moleculesmove back and forth at a fixed average location, hitting molecules inthe adjacent layer of air and so on). The air molecules themselves donot move a great distance to the end of the foam thickness. Thus, thereis no real airflow during sound transmission through a foam substrate.However, sound is dissipated by the heat which is formed by the movementof air molecules back and forth, causing friction at the cell walls.Being a compressive wave, the sound wave passes through a soft filmblocking its passage since the impingement of the molecules on a film ina generally perpendicular direction to their movement causes the film tovibrate which in turn makes the air on the other side oscillate. Thus, afew thin layers of flexible thin films, such as the unchanged interiorcore of a foam of the present invention whose surface cells have beensliced, do not excessively hurt the sound absorption capability of thefoam.

Compression as a means of opening cells may be performed by any meanssufficient to exert external force to one or more surfaces of the foam,and thus cause the cells within the base foam to burst and open.Compression during or after perforation is especially effective inrupturing the cell walls adjacent to the channels created by perforationsince a high pressure difference across the cell walls can be created.In addition, unlike needle punching, compression can result in rupturingcell walls facing in all direction, thereby creating tortuous pathsdesired for sound absorption.

The mechanical opening of closed-cells of the base foam lowers theairflow resistivity of the base foam by creating largesize pores in thecell walls and struts. In any event, regardless of the particular meansby which it does so, such mechanical opening of closed-cells within thebase thermoplastic polymer foam serves to enhance the sound absorption,sound insulation, fluid absorption, and filtering properties of thefoam.

Of course, the percentage of cells opened mechanically will depend on anumber of factors, including cell size, cell shape, means for opening(that is, perforation, slicing, compression), and the extent of theapplication of the means for opening applied to the base foam. Formaximum reduction in airflow resistivity, it is preferred that greaterthan 50 percent of the closed-cells within the base foam be opened bythe mechanical means described above, with greater than 70 percent beingmore preferred, and greater than 90 percent being most preferred. Inorder to maximize the percentage of cells opened mechanically, it ispreferred that a combination of compression and perforation be used toopen the cells. FIG. 4 depicts a cross-section of a base foam 1 of thepresent invention comprised of a multiplicity of closed-cells which havebeen elongated in the direction of extrusion 4 which have been firstcompressed, and then while the foam is compressed, perforated with amultiplicity of pointed, sharp objects 3.

In addition to the option of including a fire retardant in the polymermaterial prior to extrusion as discussed previously, the foams of thepresent invention may also be impregnated with a fire retardant afterthey have been extruded, and preferably after they have been subjectedto any additional process steps, such as elongation by pulling andmechanical opening of closed-cells.

When used in sound insulation, the foams of the present invention may beused as the core layer in a multilayered, sound insulating panelcomprised of a facing layer, the foam core layer attached thereto, and astructure to which the core layer is fixed at separated contact pointsby means of stripes, patches, dabs, or other geometrical protrusions(generally called contact points hereafter), leaving gaps between thecore layer and the structure, and in the case of long spans and/or thinfacing layers, travel stops to keep the core layer at a certain distancefrom the structure. The structure, to which the core layer is fixed atseparated contact points, can be a wall or a ceiling or any othersuitable constructional element. Alternatively, the structure can be asecond facing layer. The resulting sandwich panel can be used as apartition element or partition wall. The panels are useful inconstruction and other industries for improving sound insulationproperties of buildings and/or machinery. Examples of such panels aredescribed in WO 95/14136, published May 26, 1995.

When used as a core layer in a multilayered panel, the foams of thepresent invention may be formed into a profile in any number of ways.For example, the foams of the present invention may be profiled into astraight configuration. FIG. 9 depicts a foam of the present inventionprofiled such that it is comprised of a foam core 5 which is in the formof a straight configuration, designated 1. However, the foams of thepresent invention may also be profiled such that they exhibit a lowdynamic stiffness. For example, the foams of the present invention maybe profiled such that they are comprised of a foam core 5 to whichnarrow strips of the same or another foam 6 have been attached on thesame side at both ends of the foam core 5. The profile of FIG. 10 isdesignated U. In addition, the foams of the present invention may beprofiled such that they are comprised of a foam core 5 to which narrowstrips of the same or another foam 6 are attached alternately onopposite sides of the foam core 5 and narrow strips of the same oranother foam 6 have been attached on both sides and opposite one anotherat both ends of the foam core 5. The profile of FIG. 11 is designated W.When the foam of the present invention is so profiled and placed betweenfacer panels, these designs transform the compressive strain to thefacer panel to a flexural strain to the foam core. Given a sufficientdistance between the supporting strips, the structure provides thedesired very low dynamic stiffness. In the case of profile W, thedistances between the middle points of narrow strips 6 on the same sideof the foam core 5 are at least 250 mm, and preferably, between 300 mmand 600 mm. In the case of profile U, distances between the middlepoints of the strips are at least 350 mm, and preferably, between 450 mmto 600 mm.

The following examples of foams of the present invention are not to beconstrued as limiting. Unless otherwise indicated, all percentages,parts, and proportions are by weight

EXAMPLE 1

This Example illustrates foams to be used in this invention and a methodof preparing the foams by an extrusion process. The foams as listed inTable I were prepared using a commercial foam extrusion apparatus. Theapparatus was a screw-type extruder having two additional zones formixing and cooling at the end of the usual sequential zones for feeding,melting, and metering. An opening for blowing agent injection wasprovided on the extruder barrel between the metering and mixing zone. Atthe end of the cooling zone, there was attached a die orifice having anopening of generally rectangular shape.

A low density polyethylene having a melt index of about 0.4 dg/minute(according to ASTM D-1238, 190° C./2.16 kg) and a density of 0.922 g/cm³was fed into the extruder together with a small amount of glycerolmonostearate at a uniform rate. No nucleating agent was added in orderto keep the cell size large. The temperatures maintained at the extruderzones were 160° C. at the feeding zone, 200° C. at the melting zone,210° C. at the metering zone, and 190° C. at the mixing zone. Isobutanewas injected into the mixing zone at a uniform rate of 11.8 parts perhundred parts (pph) of polymer. The temperatures of the cooling zone andthe die block were gradually lowered to produce a good foam. At acooling zone temperature of 110° C. and a die temperature of 108° C., asubstantially closed-cell foam of about 23 kg/m³ density and a largecell size was obtained. The foam, which was about 105 mm in thicknessand about 600 mm in width, was saved (PEF1) and then pulled to reduceits thickness to approximately 80 mm, and the pulled foam was also saved(PEF2). By pulling, it was intended to enlarge the cells in thedirection perpendicular to the vertical direction. As shown in Table I,the pull not only elongated cells in the extrusion direction but alsoincreased the average cell size. A large cell size in the directionperpendicular to the vertical direction (EH average) facilitates holepunching.

TABLE I Foam Cell Size Cell Size Cell Size Cell Size Foam Density Extr.Vert. EH Av. 3D Av. Desig. (kg/m³) (mm)² (mm)¹ (mm)⁴ (mm)⁵ PEF1 23 6.25.9 5.5 5.7 5.9 PEF2 23 5.8 6.3 6.5 6.4 6.2 PEF3 32 4.9 4.0 4.3 4.2 4.4PEF4 23 2.9 2.1 2.3 2.2 2.4 PEF5* 40 1.9 1.7 1.5 1.6 1.7 *not an Examplefoam of this invention. ¹Cell size in vertical direction as determinedper ASTM D-3756. ²Cell size in extrusion direction as determined perASTM D-3756. ³Cell size in horizontal direction as determined per ASTMD-3756. ⁴Average cell size in extrusion and horizontal direction.⁵Average cell size in all three directions.

Other polyethylene foams (PEF) listed in Table 1 were prepared byessentially the same procedure as described for PEF1 and PEF2. Theisobutane level was varied for each foam produced to achieve the desireddensity and a small amount of a nucleating agent was added for cell sizecontrol. All the foams had a substantially closed-cell structure.

Test 1

Hole Punching Tests

The foams were sliced into slabs of about 55 mm in thickness, and holeswere punched through the foam slabs in a square pattern of apredetermined spacing. For punching holes in 10, 5, and 4 mm spacing, a2 mm-diameter needle was employed. The 3 mm-spaced holes were punchedwith a punching plate having a multiplicity of 1.5 mm needles secured inthe desired pattern. The degree of hole punching may be convenientlyexpressed by the hole density (that is, number of holes per squarecentimeter). Punching in a 10, 5, 4, and 3 mm square pattern results ina hole density of 1, 4, 6.25 and 11.1 holes/cm/², respectively. Fromeach foam sample a cylindrical specimen of 29 mm diameter was bored outto the entire thickness of 55 mm and the open-cell content of thespecimen was determined per ASTM D-2856 Procedure C. The open-cell dataare summarized in Table 11 for each foam specimen and punching pattern.

TABLE II Surface 10 mm Foam No. Open- Spac- 5 mm 4 mm 3 mm Type Holes¹Cell² ing³ Spacing⁴ Spacing⁵ Spacing⁶ PEF1 63 55 84 90 94 95 PEF2 77 5981 94 95 95 PEF3 ND 41 53 82 87 95 PEF4 ND 23 61. 71 78 92 PEF5* ND *18 *30  *47  *66  *72  *not an Example foam of this invention. ¹Open-cellcontent of as-extruded foams in percent ND = not determined. ²The volumeof the cut surface cells as a percentage of the foam volume (per ASTMD-2856). ³Open-cell content of foam body hole-punched in 10 mm spacingin percent. ⁴Open-cell content of foam body hole-punched in 5 mm spacingin percent. ⁵Open-cell content of foam body hole-punched in 4 mm spacingin percent. ⁶Open-cell content of foam body hole-punched in 3 mm spacingin percent.

The data clearly indicated that the larger the cells, the easier it wasto develop open-cells by hole punching. In order to punch a majority ofthe cells, the hole spacing needed to be equivalent to or smaller thanthe cell size. Since punching holes to the greater density was the morecostly, a foam having the larger cell size was preferred. Punching onehole per square centimeter is commercially practiced on certain foamshaving cell size less than 2 mm. Four holes per square centimeter can bereadily applicable. Punching greater than 4 holes per square centimetermay not be impossible, but is difficult in practice. In addition, thespecimen of a macrocellular foam (for example, PEF1 and PEF2), withouthole punching, already had a high level of open cells developed. Much ofthe high open-cell content comes from the cut surface cells of thespecimen. For example, the surface cut cells of PEF2 amounted to about59 percent out of the total 77 percent open-cell content of the foam.

Test 2

Compression Test

Foam PEF1 from Example 1 was first punched with a 2 mm-diameter needlein a 5 mm by 5 mm square pattern. The punched foam had an open-cellcontent of approximately 93.5 percent (as determined by ASTM D-2856Procedure C). A foam specimen of 11 cm by 11 cm cross-section and 7 cmin thickness was cut from the foam plank and compressed in the thicknessdirection using a press until the thickness became 5 mm. During thecompression, a popping sound indicating cell breakage was heard. Theopen-cell content of the foam increased to 96.7 percent, which is closeto the maximum possible open-cell content of the foam (that is, about 97percent). Evidently, most of the remaining closed-cells were burst openby compression.

Test 3

Airflow Test

This test showed that larger flow channels were more readily created bypunching holes in a larger-celled foam than a smaller-celled foam. Theapparatus used in this test was an airflow tester similar to thosedescribed in ASTM D-3574 and ISO 9053 (Method A). It consisted of an airpiston of 10 cm inside diameter which was driven by the drive of aninstron tester, a sample holder made of a plastic pipe of 7 cm insidediameter and a cap, a water manometer and assorted connecting tubes. Airwas pumped at a fixed rate through a specimen loaded in the holder andthe pressure drop across the specimen was measured using the manometer.

In practice, three foams of different cell sizes were selected in thistest: two polyethylene foams prepared in Example 1 PEF4 and PEF5, and apolypropylene foam. The polypropylene foam was a coalesced strand foamprepared on a foam extrusion line having a similar configuration as onein Example 1 using a die having multiple holes. The polypropylene foam(PPF) had a cell size (3D average) of about 0.4 mm, a density ofapproximately 17 kg/m³, and an open-cell content of 84 percent (ASTMD-2856 Procedure A). The foams were sliced parallel to the extrusiondirection to 35 mm-thick slabs. A 6.4 cm-diameter circular specimen wascut out of the slab and loaded in the sample holder. A caulking materialwas used to seal off the edges against the pipe surface. First, thepressure drop across the specimen was measured at a slow air rate (at apiston speed in the order of 1 to 1.5 mm/minute) to ensure a propersealing at the edges and to determine the airflow resistance of thenascent foam. Then, a hole was punched through the foam specimen with aneedle of predetermined diameter, and the pressure drop at anappropriate flow rate was measured. The procedure was continued until 9holes were punched into the specimen. The airflow per hole wascalculated from the slope of the regression line between the airflow perunit pressure gradient (pressure drop/thickness of the specimen) and thenumber of holes. The airflow indicated how well air flows through ahole. The airflow data for foam specimens punched with 2, 3 and 4 mmneedles are summarized in Table III in units of m⁴/GPa.s (cubic meterper giga Pascal/meter per second). For a given needle size thelarger-celled foam developed the higher airflow holes than thesmaller-celled foam. In addition the larger needle developed thehigher-airflow holes for all foams than the smaller needle. The effectof the needle size on the airflow was greater with a foam having thelarger cell size.

TABLE III Airflow Foam 2 mm Needle 3 mm Needed 4 mm Needle Type(m⁴/GPa·s)¹ (m⁴/GPa·s)² (m⁴/GPa·s)³ PEF4 0.23 1.0 2.7 PEF5 0.17 0.72 1.2*PPF 0.17 0.46 0.49 *Not an Example of this invention. ¹Airflow througha hole punched with a 2 mm needle through foam body. ²Airflow through ahole punched with a 3 mm needle through foam body. ³Airflow through ahole punched with a 4 mm needle through foam body.

Test 4

Comparison of Airflow Resistivity and Sound Absorption Among Foams ofVarying Cell Size

The apparatus used in this Example is a Model 4206 acoustical impedancetube and Model 3555 signal analyzer, both supplied by Brueel and KjaerA/S, Naerum, Denmark. This apparatus is used to measure a normalincidence sound absorption coefficient of a foam according to the methoddescribed in ASTM E-1050. In practice, specimens of 29 mm in diameterand 35 mm in thickness were bored out of the foams used in Test 3. Sevenholes were punched into a specimen in the thickness direction using aneedle of a chosen diameter. The holes were approximately equally spacedin a triangular pattern with one of them punched at the center and therest at the corners of a hexagon enhaving 9 mm sides. The hole densityis calculated to be approximately 1.06 holes/cm². Needles of 2, 3 and 4mm diameter were employed. The nascent foam with no holes was alsotested for comparison. The specific airflow resistance of the specimensof hold-punched foams was calculated from the per-hole airflow shown inTable III. The specific airflow resistance of the nascent foams wasmeasured directly. The specific airflow resistance and the soundabsorption coefficients are summarized in Table IV.

TABLE IV Needle Specific Airflow Sound Absorption Coefficient Test FoamSize Resistance Freq. Type Type (mm)¹ (1000 Rayls)² 500 Hz³ 1000 Hz⁴2000 Hz⁵ Maximum⁶ (Hz)⁷ 4.1*  PEF4 None 4056 0.11 0.11 0.16 NE NE 4.2 PEF4 2 14.4 0.42 0.34 0.28 0.50 700 4.3  PEF4 3 3.2 0.31 0.53 0.68 0.75800 4.4  PEF4 4 1.2 0.29 0.63 0.52 0.83 810 4.5*  PEF5 None 4718 0.050.06 0.09 NE NE 4.6*  PEF5 2 19.4 0.13 0.07 0.14 0.16 350 4.7*  PEF5 34.6 0.29 0.13 0.19 0.30 480 4.8*  PEF5 4 2.9 0.32 0.20 0.21 0.33 5404.9*  PPF None 2926 0.05 0.06 0.09 NE NE 4.10* PPF 2 20.0 0.14 0.09 0.110.23 280 4.11* PPF 3 7.2 0.25 0.12 0.15 0.31 350 4.12* PPF 4 6.7 0.420.21 0.18 0.43 580 *Not an Example of this invention. ¹The size of theneedle used to punch holes. ²Specific flow resistance of the 35 mm-thickspecimen measured in thousand Rayls. ³Sound absorption coefficient at afrequency of 500 Hz determined per ASTM E-1050. ⁴Sound absorptioncoefficient at a frequency of 1000 Hz determined per ASTM E-1050. ⁵Soundabsorption coefficient at a frequency of 2000 Hz determined per ASTME-1050. ⁶The maximum sound absorption coefficient at a frequency below1600 Hz; NE = not existing. ⁷The frequency where the maximum absorptionoccurs.

All nascent foams have a very high specific airflow resistance and holepunching dramatically reduces the airflow resistance. Again, the largerthe cells the foam had and the larger the needles used, the greater thereduction in the specific airflow resistance. The nascent foams absorbsound poorly. Clearly, the hole-punched foams absorb sound better thanthe nascent foams. In general, the smaller the specific airflowresistance, the greater the sound absorption coefficient the foam had.The sound absorption curves of the hole-punched foams generally looklike those shown in FIG. 5, where foams punched with a 3 mm-diameterneedle are compared. The sound absorption curve goes through a maximumat a frequency below 1000 Hz, declines and then goes through severalhumps in the measurement frequency range of 6400 Hz. Since the soundabsorption characteristics below 2000 Hz, and more importantly, thosebelow 1000 Hz, are of primary importance, those data are represented inTable IV and FIG. 5. In FIG. 5, the large-celled PEF4 foam (Test No.4.3) absorbs the sound far better than the smaller-celled PEF5 (Test No.4.7) and PPF (Test No. 4.11) even though the foam specimens were punchedwith the same needle at the same hole density. The difference in thesound absorption capability does not solely come from the difference inthe specific airflow resistance. For example, foam PEF5 punched with a 4mm needle absorbed sound far worse than foam PEF4 punched with a 3 mmneedle even though the former had the lower specific airflow resistancethan the later. It can be deduced from Test 1 that the larger-celledfoam sees the greater of its volume opened up by hole punching than thesmaller-celled foam.

Test 5

Comparison of Open-Cell Content and Sound Absorption Among Foams ofLarge Cell Size

The effect of hole spacing on the sound absorption and open-cell contentwas investigated in this test. The large-celled foams as prepared inExample 1, nascent and hole-punched, were subjected to the soundabsorption test as in Test 4. Specimens were the same as used inopen-cell test in Example 1 except that their lengths were shortened toapproximately 35 mm. The data are summarized in Table V.

TABLE V Open- Needle Cell Sound Absorption Coefficient Test Foam SpacingContent Freq. No. Type (mm)¹ (%)² 500 Hz³ 1000 Hz⁴ 2000 Hz⁵ Maximum⁶(Hz)⁷ 5.1  PEF2 None 77 0.46 0.66 0.58 0.95  730 5.2  PEF2 10 81 0.350.79 0.72 0.98  820 5.3  PEF2  5 84 0.14 0.65 0.69 0.87 1280 5.4  PEF2 4 95 0.13 0.63 0.61 0.85 1290 5.5  PEF2  3 95 0.29 0.72 0.69 0.93 13605.6  PEF3 None ND 0.31 0.47 0.49 0.72  730 5.7  PEF3 10 53 0.41 0.520.51 0.76  730 5.8  PEF3  5 82 0.17 0.78 0.52 0.91 1200 5.9  PEF3  4 870.18 0.83 0.51 0.93 1140 5.10 PEF3  3 95 0.38 0.94 0.99 0.95  960 5.11PEF4 10 61 0.27 0.74 0.44 0.87  850 5.12 PEF4  5 71 0.22 0.97 0.54 0.991060 5.13 PEF4  4 79 0.17 0.84 0.52 0.98 1200 5.14 PEF4  3 92 0.41 0.910.80 0.95  880 ND = not determined. None = no holes punched (nascentfoam). ¹The spacing between the holes in a square pattern. ²Open-cellcontent as determined per ASTM D-2856 Procedure C; the same data as inTable I. ³Sound absorption coefficient at 500 Hz determined per ASTMD-1050. ⁴Sound absorption coefficient at 1000 Hz determined per ASTMD-1050. ⁵Sound absorption coefficient at 2000 Hz determined per ASTMD-1050. ⁶The maximum sound absorption coefficient at a frequency below1600 Hz. ⁷The frequency where the maximum absorption occurs.

All foams showed active sound absorption capability. Surprisingly, thenascent large-celled foams display excellent sound absorptioncapabilities (Test No. 5.1 and 5.6). The full absorption curves of thesefoams and nascent PEF4 foam (Test No. 4.1) are compared in FIG. 6. Thesuperior sound absorption capabilities of the large-celled foams areevident in FIG. 6. The cells cut open at the surfaces of the foamspecimens were inferred to contribute to the outstanding soundabsorption properties of the foams. In the case of macrocellular PEF2,the nascent foam absorbed sound better than the hole punched foam andthe sound absorption capability tends to deteriorate as the hole densitywas increased for holes punched with a 2 mm needle. This trend is moreclearly seen in FIG. 7. Sound absorption was affected by both theopen-cell content and the specific airflow resistance. It is known thattoo low a specific airflow resistance is detrimental to the soundabsorption. This offers an explanation as to why the sound absorptiondecreased as the hole density was increased. An apparent reversal of thetrend with 3 mm hole-spaced foam was probably due to the use of asmaller needle (1.5 mm diameter). In PEF3, the foam specimenhole-punched at 10 mm spacing provided the best sound absorption (TestNo. 5.7). In PEF4, which had a relatively small cell size, a foamspecimen with holes at 5 mm spacing (Test No. 5.12) absorbed soundslightly better than one with holes at 10 mm spacing (Test No. 5.11).

Test 6

Effect of Faced Film on Sound Absorption

The effect of skin and an attached film on the sound absorptionproperties of hole-punched PEF2 foam specimens was investigated in thistest. A DAF 899 brand adhesive film (commercially available by The DowChemical Company) was used as the facer for the foam specimen. The filmwas prepared from PRIMACORE* 3330 ethylene/acrylic acid copolymer(Trademark of The Dow Chemical Company). The film of approximately 37micrometer in thickness was ironed on to the surface of a foam specimenwhose skins were removed. The iron was lined with a Teflon™tetrafluoroethylene fluorocarbon polymer (Trademark of Du Pont deNemours Co.) sheet in order to prevent the film from sticking to theiron. Both foams punched in 10 mm and 5 mm spacing were employed for thetests of this Example. The film-faced specimens were compared with thosewith skins removed. In the case of the foam specimen with holes punchedin 10 mm spacing, the test included a specimen having the skin left inone side. The thickness of all specimens was fixed at 35 mm and thesound absorption coefficients of the specimens were determined with thesurface with film or skin faced to the sound source. The results of thesound absorption tests are set forth in Table VI and Figure VIII, wherethe results of Tests 6.4 and 6.5 are compared:

TABLE VI Sound Absorption Coefficient Needle Specimen Freq. Test SpacingSurface 250 Hz 500 Hz 1000 Hz 1600 Hz Maximum (Hz) No. (1) (2) (3) (4)(5) (6) (7) (8) 6.1 10 skin 0.09 0.55 0.91 0.41 1.00 1030 removed 6.2 10with skin 0.19 0.32 0.86 0.31 0.96  920 6.3 10 with film 0.20 0.28 0.840.28 0.92  920 6.4  5 skin 0.05 0.24 0.59 0.78 0.82 1280 removed 6.5  5with film 0.47 0.44 0.72 0.45 0.94  760 (1)The spacing between holes insquare pattern in mm

As shown in the table and FIG. 8, the film attachment dramaticallyimproved the sound absorption performance of the foams at lowfrequencies. In the case of the foam specimen hole-punched in 5 mmspacing, the film enhanced sound absorption at the entire frequencyrange below 1000 Hz.

Test 7

Sound Insulation Performance as a Low-Stiffness Profile Insert inW-shape

In this test, the sound insulation performance of hole-punched foams asan insert for a double-leaf partition was investigated. The soundtransmission tests were done at a CEBTP laboratory. The soundtransmission reduction facility at CEBTP had a source of 55 m³ volumeand a receiving room of 51 m³. In the middle of the dividing wall of 36cm-thickness, there was provided an opening 0.96 m in width, 1.96 m inthickness, and 12 cm in depth when seen from the source room. The holewas enlarged to 1.08 m by 2.06 m size in the remainder of the wallthickness, where the test panel was to be installed. A panel of 1.05 mby 2.05 m size was installed in the opening. The sound transmission lossthrough the panel installed in the opening was measured and calculatedper a method described in ISO R 717-1968.

In practice, large-celled polyethylene foams prepared in Example 1 werepunched in a selected hole pattern with a selected needle as shown inTable VII. An acoustical polyurethane foam was also included in the testfor comparison. The foams were profiled into a low-stiffnessconfiguration (W) as shown in the notes section of Table VI. A straightinsert (I) was also tested for a foam for comparison. Pressed woodsheets of 13 mm thickness were used as the lacers for all panels in thisExample. The panels were put together using a commercial panel glue. Theperipheral gaps between the wall and the edge of the specimen werefilled with a fiber glass and then sealed off with a caulking material.

TABLE VII Hole Punching Needle Hole Test Foam Configu- Size SpacingOpen-Cell SRI No. Type ration¹ (mm)² (mm)³ Content (%)⁴ (dB(A)) 7.1 PEF2W 3 5 94 42.2 7.2 PEF2 W 2 5 94 42.6 7.3 PEF2 W 2 10 81 40.3 7.4 PEF3 W4 5 77 40.6 7.5 PEF3 W 3 5 74 41.2 7.6 PEF3 W 2 5 82 40.0 &.7 PEF4 W 3 567 40.9 7.8 PEF4 W 2 5 71 40.2 7.9 PEF4 W 4 10 55 39.1 7.10 PEF4 W 3 1052 38.5 7.11 PEF4 W 2 10 52 37.6 7.12* PEF5 W 4 10 37 36.6 7.13* PUF WNone — 96 44.9 7.14* PEF2 W 2 5 94 34.2 *Not an Example of thisinvention. ¹W = Insert with a 35 mm-thick foam core supported by 40mm-wide and 7 mm-thick strips spaced by 337 mm (distance between themiddle points of the strips on the same side) alternately on theopposite side contacting the facers (see FIG. 11) I = a straight slabcore of 54 mm in thickness (see FIG 9). ²Diameter of the needle used topunch the holes in millimeters. ³Spacing between holes punched in asquare pattern in millimeters. ⁴Open-cell content in percent determinedper ASTM D-2856 Procedure C, with a cylindrical specimen of 45 mm indiameter and 35 mm in length. ⁵Sound reduction index measured at CEBTPin deciBells (A).

The sound transmission loss data through the panels are summarized interms of A-weighted sound reduction indices for a pink noise. The dataare arranged in the general order of the cell size, needle size, and thehole density. An examination of the data revealed the parametersimpacting the sound insulation performance: the insert configuration;the foam type; open-cell content; and the airflow resistance (the holedensity and size of the needle). Foam cores of the low-stiffness coreconfiguration (W) provided a far better sound insulation than a straightone (I) (Compare Tests 7.2 and 7.14). Among hole-punched foams with theW configuration, the open-cell content had the greatest impact on soundinsulation followed by airflow resistance. PEF2 foam profileshole-punched to have greater than 90 percent open-cells provided a soundreduction index (SRI) between 42 to 43 dB(A). The performance, while alittle lower than that of a polyurethane foam, was quite satisfactory.Foam specimens made from PEF2, PEF3, and PEF4 foams, containing 67 to 82percent open-cell, demonstrated an SRI in the range of 40.0 to 41.2dB(A). PEF4 specimens hold-punched at a 10 mm by 10 mm pattern had anopen-cell content of 52 to 55 percent and a marginal SRI in the range of37.6 to 39.1 dB(A). Among them, a specimen hold-punched with the largeneedle yields the greater sound insulation performance. The small-celledPEF5 records an unsatisfactory 36.6 dB(A) performance.

Test 8

Sound Insulation Performance as a Low-Stiffness Profile Insert inU-shape

In this test, PEF2 foam hole-punched with a 2 mm needle at a 5 mm by 5mm pattern was cut to a different low-stiffness foam profile as shown inthe notes of Table VIII, and tried as an insert for a double-leaf panel.The configuration (U) consisted of a 42 mm-thick straight foam slab,which had supports of 40 mm width and 7 mm thickness at the ends. Thesound insulation performance of the U foam-core was tested by the sameprocedure as in Test 6. The data are summarized in Table VIII.

TABLE VIII Hole Punching Needle Hole Open Cell Test Foam Size SpacingContent SRI No. Type Configuration¹ (mm)² (mm)³ (%) (dB(A)) 8.1 PEF2 U 25 94 43.0 ¹1.05 m-wide insert with the shape as shown in FIG. 10 with afoam body of 42 mm in thickness and two supports of 40 mm in width and 7mm in thickness at the ends. ²Diameter of the needle used to punch theholes in millimeters. ³Spacing between holes punched in a square patternin millimeters. ⁴Open-cell content in percent determined per ASTM D-2856Procedure C. with a cylindrical specimen of 45 mm in diameter and 35 mmin length. ⁵Sound reduction index measured at CEBTP

As shown, the hole-punched macrocellular foam when inserted in a Uprofile in a double-leaf panel provided a satisfactory sound insulationperformance.

Test 9

Water Absorption

A 12 cm by 12 cm by 3.5 cm specimen was cut out of the hole punchedpolyethylene foam as used in Test 8 and submerged in plain tap water forapproximately 30 seconds. The specimen was taken out of the water andweighed after the surface water was dripped away. The specimen was foundto weight 10.5 times more than the specimen prior to water-soaking. Thewater could be easily squeezed out of the specimen. The test resultsindicate that such a hole-punched macrocellular foam can be used to makematerials requiring water absorption as in a cleaning pad.

Test 10

Impregnation of Fire Retardant

Foam specimens of approximately 31 cm by 53 cm by 1 25 cm were preparedfrom the hole-punched foam as used in Test 8. A 30 percent aqueoussolution was prepared of a fire retardant material provided by NorfireAS of Norway. The proprietary fire retardant was indicated to contain 12to 15 percent ammonium sulfate, 1 to 4 percent each of sodiumtetraborate decahydrate, sodium chloride, and sodium phosphate. Inpractice, a foam specimen was submerged in the fire retardant solutioncontained in a shallow pan. The foam specimen was observed to quicklyabsorb the fire retardant solution. When taken out of the solution, thespecimen retained most of the solution absorbed therein. In Test No.10.3, the solution was squeezed out of the foam specimen. Thesolution-impregnated specimens were weighed, dried for four hours at anambient temperature, then in an oven maintained at 60° C. overnight. Theweights of the foam specimens were monitored during drying. In TestsNos. 10.2 and 10.3, the fire retardant crystals loosely hanging on thesurface of the foam specimens were scraped away and the final retentionof the fire retardant in the foam was determined. The foam specimenswere subjected to a limiting oxygen index (LOI) test. As shown in TableIX, the foam specimens absorb large amounts of solution and water driesout of the open-celled foam with relative ease. The specimen from whichthe solution has been squeezed out (Test No. 10.3) is shown to lose mostof the absorbed water during 6 hour drying (4 hours at ambienttemperature and 2 hours at 60° C.). The fire retardant-pregnated foamsexhibit relatively high LOIs.

TABLE IX Weight Gained Weight After Drying Test Squeezed Gain AfterAmbient @ 60° C. @ 60° C. @ 60° C. Final FR LOI No. ? App.² 4 h (g)³ 2 h(g)⁴ 4 h (g)⁵ 16 h (g)⁶ Cont. (g) (%) 10.1 No 13.5 7.7 4.2 3.2 2.62.6 >31 10.2 No 12.7 6.0 3.8 2.9 2.3 1.1 23.5 10.3 Yes  4.0 1.8 1.2 1.11.0 0.7 22.3 ¹No = the solution was not squeezed out; Yes = the solutionwas squeezed out after application. ²Amount of solution absorbed in agram of foam body. ³Amount of solution remaining in a gram of foam bodyafter drying for 4 hours at an ambient temperature. ⁴Amount of solutionremaining in a gram of foam body after drying for 2 hours at 60° C.⁵Amount of solution remaining in a gram of foam body after drying for 4hours at 60° C. ⁶Amount of solution remaining in a gram of foam bodyafter drying for 16 hours at 60° C. ⁷Final amount of the solid fireretardant retained in a gram of foam body after scraping off. ⁸LimitingOxygen Index: minimum concentration of oxygen, expressed as volumepercent, in a mixture of oxygen and nitrogen that will just supportflaming combustion of a material initially at room temperature under theconditions of this test.

EXAMPLE 2

The apparatus used in this Example is a commercial foam extrusion linehaving essentially the same configuration as used in Example 1. In thisExample, three additional macrocelluar polyolefin foams were preparedfrom a low density polyethylene resin and a blend of the resin with anethylene-styrene interpolymer (ESI) resin. The polyethylene resin had amelt index of 1.8 dg/minute (at 190° C./2.16 kg) and a density of 0.923g/cm³. The ESI resin used was INDEX DS 201 brand produced by The DowChemical Company using a constrained geometry catalyst. Theapproximately 70/30 styrene/ethylene copolymer resin has a melt index(at 190° C./12.16 kg) of 1.1. Foams were prepared from a 70/30 blend ofthe polyethylene resin and the ES copolymer resin as well as thepolyethylene resin.

The foam expansion procedure was essentially the same as in Example 1.The foams prepared in this Example are listed in Table X. Isobutane wasused as the blowing agent at 9.13 pph for preparation of all of thefoams. As in Example 1, a small mount of glyerol monostearate was addedfor the control of foam dimensional stability. For preparation of thepolyethylene foam (PEF6) and ESF1 PE/ESI blend foam, a small amount oftalc was added in a concentrate form (50 percent talc in the samepolyethylene) for cell size control. The effective talc level was 0.068pph for PEF6 foam and 0.034 pph for ESF1. No nucleator was added toESF2.

Both ESF1 and ESF2 foams were prepared from the same 70/30 blend ofpolyethylene and ESI resin. A small amount (0.05 pph) of antioxidant(Irganox 1010 from Ciba Geigy Corp.) was incorporated into all threefoams. At a cooling zone temperature of approximately 110° C. and dietemperature of 111° C., all three formulations produced excellentquality foams. The cross-sectional sizes of the foams were approximately60 mm in thickness and 620 mm in width. As shown in Table X, the foamshave approximately 29 to 30 kg/m³ density and large cell sizes. Theaverage cell sizes ranged from 5.6 to 6.7 mm.

TABLE X Cell Cell Foam Foam Size Size Cell Size Cell Size Cell SizeDesign- Density Vert. Extr. Horiz. EH Av. 3D Av. ation (kg/m3) (mm) (mm)(mm) (mm) (mm) PEF6 30 7.4 8.0 6.8 6.4 6.7 ESF1 29 5.8 6.0 4.9 5.5 5.6ESF2 29 6.8 6.8 6.0 6.4 6.5 Notes: (1) through (5) = the same as inTable 1

Test 11

Open-Cell Development by Hole Punching and Compression

The foams were skived to slabs of 35 mm thickness and punched holes in10 mm and 5 mm spacing with a 2 mm diameter needle. Specimens ofcylindrical shape having 45 mm diameter was bored out of the slabs. Oneof the specimens having 5 mm hole spacing was compressed to 95 percentof its thickness to further develop open-cells. All of the compressedfoams recovered well to near their original thickness. Open-cells weredetermined using the cylindrical specimens of 45 mm diameter and 35 mmthickness. The open-cell contents were determined per ASTM D2856procedure C. As shown in Table XI, the desired high level of open-cellsdeveloped by hole punching. Since hole punching in 5 mm spacing alreadyprovided open-cell contents in the range from 92 to 95 percent, afurther development of open-cells by compression was small. Asanticipated, ESF1 having slightly smaller cells than the rest developsopen-cells slightly less.

TABLE XI 5 mm Spacing 10 mm 5 mm & Foam Spacing Spacing CompressionDesig. (1) (2) (3) PEF6 72.5 94.7 95.3 ESF1 69.2 92.6 94.5 ESF2 72.994.4 95.7 (1) Open-cell content of foam body hole punched in 10 mmspacing in percent. (2) Open-cell content of foam body hole punched in 5mm spacing in percent. (3) Open-cell content of foam body hole punchedin 10 mm spacing and then compressed to 95% of the original thickness inpercent.

Test 12

Mechanical and Vibration Damping Properties

The mechanical and vibration damping properties of the hole-punchedfoams were determined in order to know the suitability of the foammaterials for use as an insert in a sandwich panel. The dynamicstiffness and loss factor were determined using a vibration table. Adisc-shape foam specimen of 10 cm in diameter and 35 mm in thickness wasmounted on a vibration table. On the top of the specimen, there wasloaded a particle circular particle board of the same diameter. Thesurface weight of the particle board was approximately 10 kg/m². Oneaccelerometer was attached under the table and the other on the topsurface of the particle board weight. The table was shaken vertically inrandom frequencies and the resonance frequency and damping ratio weredetermined from the accelerometer signals using a Brueel and Kjaer Model3555 signal analyzer as used in Test 4. The dynamic stiffness wascalculated from the resonance frequency, and the loss factor from thedamping ratio. The mechanical and vibration properties of the foams aregiven in Table XII.

TABLE XII Needle Compress. Compress. Tensile Tensile Tensile DynamicLoss Foam Spacing Strength Modulus Strength Modulus Elong. StiffnessFactor Desig (1) (2) (3) (4) (5) (6) (7) (8) PEF6 10 25 747 154 1260  303.5 0.41 PEF6  5 22 566 ND ND ND 1.7 0.35 ESF1 10 17 482 131 790 51 4.80.46 ESF1  5 15 362 ND ND ND 3.2 0.48 ESF2 10 16 464 134 814 54 5.0 0.39ESF2  5 14 332 ND ND ND 3.1 0.46 Note: ND = Not determined. (1)Thespacing between holes in square pattern in millimeters. (2)Compressedstrength in the vertical direction in kiloPascals determined per ASTMD-3575. (3)Compressive modulus in the vertical direction in kiloPascalsdetermined per ASTM D-3575. (4)Tensile strength at break in the verticaldirection in kiloPascals determined per ASTM D-3575. (5)Tensile modulusin the vertical direction in kiloPascals determined per ASTM D-3575.(6)Tensile elongation in the vertical direction in percent determinedper ASTM C-3575. (7)Dynamic stiffness in megaNewtons per cubic meterdetermined with a 35 mm thick foam specimen with a surface weight of 10kilograms per square meter. (8)Loss factor determined at the samecondition as for determination of dynamic stiffness.

As shown in the table, the foams have adequate compressive strength andtensile toughness for use as a sandwich panel insert. As anticipated,blending in the ESI resin made the foam softer. The PE/ESI blended foamswere tougher as indicated by greater elongation. Punching holes at ahigher density of 5 mm spacing results in a minor reduction in thecompressive strength. The higher hole-punching density was shown to havea greater impact on the dynamic stiffness. Advantageously, the dynamicstiffness was reduced to the greater extent than the compressivestrength. All foams exhibit good damping characteristics with lossfactor in the range from 0.35 to 0.48. As expected from the highlydamping ESI resin, PE/ESI blended foams, in general, had higher lossfactors than the PE foam, but the difference among the 10 mm-spaced holefoams was small. Interestingly, the PE/ESI blended foams saw anadvantageous increased in the loss factor as more holes were punched. Incontrast the PE foam experienced a decreased in the loss factor as moreholes were punched therein.

Test 13

Sound Absorption Coefficient

The sound absorption coefficients of the hole-punched macrocellularfoams were measured per ASTM E-1050 using the apparatus as described inTest 4. As shown in Table XIII, the polymer composition had a minoreffect on the sound absorption capability of the foam. As observedbefore, a higher hole density deteriorated the sound absorptioncapability. The good sound absorption performance of a macrocelluar foamwas once again substantiated by the foams punched at 10 mm spacing.

TABLE XIII Sound Absorption Coefficient Needle Freq. Foam Spacing 250 Hz500 Hz 1000 Hz 2000 Hz Maximum (Hz) Desig. (1) (2) (3) (4) (5) (6) (7)PEF6 10 0.21 0.77 0.60 0.75 1.00 800 ESF1 10 0.16 0.79 0.46 0.61 0.92740 ESF2 10 0.15 0.77 0.50 0.64 0.95 780 PEF6  5 0.08 0.28 0.96 0.430.99 960 ESF1  5 0.09 0.29 0.96 0.67 0.98 1020  ESF2  5 0.08 0.25 0.960.59 0.99 1030  Notes: (1)The spacing between holes in square pattern inmillimeters. (2)Sound absorption coefficient at a frequency of 250 Hzdetermined per ASTM E-1050. (3)Sound absorption coefficient at afrequency of 500 Hz determined per ASTM E-1050. (4)Sound absorptioncoefficient at a frequency of 1000 Hz determined per ASTM E-1050.(5)Sound absorption coefficient at a frequency of 2000 Hz determined perASTM E-1050. (6)The maximum sound absorption coefficient at a frequencybelow 1600 Hz. (7)The frequency where the maximum occurs.

What is claimed is:
 1. A process for preparing a cellular thermoplasticpolymer foam structure comprising the steps of: a) providing a firstcellular thermoplastic polymer foam structure with an average celldiameter of from 2 mm to 15 mm, wherein at least some portion of thecells thereof are closed-cells; and b) applying a means for openingclosed-cells in a cellular thermoplastic polymer foam to at least someportion of at least one surface of said first thermoplastic polymer foamstructure, such application being sufficient to result in a cellularthermoplastic polymer foam structure having an average cell diameter offrom 2 mm to 15 mm wherein greater than 50 percent of the cells havebeen opened by the application of the means for opening closed-cells ina cellular thermoplastic polymer foam.
 2. A process according to claims1 wherein the first cellular thermoplastic polymer foam structure issubstantially closed-celled.
 3. A process according to claim 1 whereinthe first cellular thermoplastic polymer foam structure is substantiallyopen-celled.
 4. A process according to claim 1 wherein the firstcellular thermoplastic polymer foam structure has average cell diameterof from 2 mm to 10 mm.
 5. A process according to claim 4 wherein thefirst cellular thermoplastic polymer foam structure has an average celldiameter of from 3 mm to 10 mm.
 6. A process according to claim 5wherein the first cellular thermoplastic polymer foam structure has anaverage cell diameter of from 4 mm to 8 mm.
 7. A process according toclaim 1 wherein the first cellular thermoplastic polymer foam structureis prepared from an olefinic polymer.
 8. A process according to claim 7wherein the olefinic polymer is selected from ethylenic polymers,copolymers, or blends thereof.
 9. A process according to claim 7 whereinthe olefinic polymer is polypropylene.
 10. A process according to claim9 wherein the thermoplastic polymer further comprise(s) polyethyleneresin(s).
 11. A process according to claim 8 wherein the ethylenicpolymer is a low density polyethylene.
 12. A process according to claim10 wherein the polyethylene resin(s) comprise a low densitypolyethylene.
 13. A process according to claim 12 wherein thethermoplastic polymer further comprises an ethylenic copolymer and a lowdensity polyethylene.
 14. A process according to claim 1 wherein greaterthan 70 percent of the cells of the cellular thermoplastic polymer foamstructure have been opened by the application of the means for openingclosed-cells in a cellular thermoplastic polymer foam.
 15. A processaccording to claim 1 wherein greater than 90 percent of the cells of thecellular thermoplastic polymer foam structure have been opened by theapplication of the means for opening closed-cells in a cellularthermoplastic polymer foam.
 16. A process according to claim 1 whereinthe cellular thermoplastic polymer foam structure has an airflowresistivity of less than 800,000 Rayls/m.
 17. A process according toclaim 16 wherein the cellular thermoplastic polymer foam structure hasan airflow resistivity of less than 400,000 Rayls/m.
 18. A processaccording to claim 17 wherein the cellular themoplastic polymer foamstructure has an airflow resistivity of less than 100,000 Rayls/m.
 19. Aprocess according to claim 18 wherein the cellular thermoplastic polymerfoam structure has an airflow resistivity of less than 50,000 Rayls/m.20. A process according to claim 1 wherein said means for opening isselected from perforation, slicing, compression, or combinationsthereof.
 21. A process according to claim 20 wherein said means foropening includes slicing.
 22. A process according to claim 20 whereinsaid means for opening includes compression.
 23. A process according toclaim 22 wherein said means for opening is perforation followed bycompression.
 24. A process according to claim 20 wherein said means foropening includes perforation.
 25. A process according to claim 24wherein the perforation comprises one or more square patterns.
 26. Aprocess according to claim 24 wherein the perforation is performed in aone or more triangular patterns.
 27. A process according to claim 24wherein the means for opening is a compression followed by perforation.28. A process according to claim 24 wherein the perforation is performedin a manner which results in the perforations being spaced one fromanother at distances which are no greater than two times the averagediameter of the cells within the first cellular thermoplastic polymerfoam structure.
 29. A process according to claim 28 wherein theperforation is performed in a manner which results in the perforationsbeing spaced one from another at distances which are no greater than 1.5times the average diameter of the cells within the first cellularthermoplastic polymer foam structure.
 30. A process according to claim29 wherein the perforation is performed in a manner which results in theperforations being spaced one from another at distances which areapproximately equal to the average diameter of the cells within thefirst cellular thermoplastic polymer foam structure.
 31. A processaccording to claim 29 wherein the perforation is performed in a mannerwhich results in the perforations being spaced one from another atdistances which are less than the average diameter of the cells withinthe first cellular thermoplastic polymer foam structure.
 32. A processaccording to claim 24 wherein the perforation comprises puncturing thefirst cellular thermoplastic polymer foam structure with one or morepointed, sharp objects.
 33. A process according to claim 32 wherein thepointed, sharp objects is selected from needles, pins, spikes, or nails.34. A process according to claim 31 wherein the perforation comprisespuncturing the first cellular thermoplastic polymer foam structure bydrilling, laser cutting, high pressure fluid cutting, air guns, orprojectiles.
 35. A process according to claim 14 wherein thethermoplastic polymer comprise(s) a low density polyethylene combinedwith polypropylene and/or an ethylene copolymer.
 36. A process accordingto claim 35 wherein the cellular thermoplastic polymer foam structurehas an average cell size greater than 4 mm.
 37. A process according toclaim 1 wherein the cellular thermoplastic polymer foam structure has anaverage cell size greater than 4 mm.
 38. A process according to claim 1,wherein the cellular thermoplastic foam structure is an extruded foam inwhich the cells are elongated and the orientation of cell elongation isin the extrusion direction.
 39. A process according to claim 36, whereinthe cellular thermoplastic foam structure is an extruded foam in whichthe cells are elongated and the orientation of cell elongation is in theextrusion direction.
 40. A process according to claim 1, wherein thecellular themoplastic polymer foam structure is in a coalesced strandform.
 41. A process according to claim 36, wherein the cellularthemoplastic polymer foam structure is in a coalesced strand form.
 42. Aprocess according to claim 1, wherein the cellular thermoplastic polymerfoam structure is in the form of non-crosslinked beads.
 43. A processaccording to claim 1, wherein the cellular thermoplastic polymer foamstructure has an average cell diameter greater than 2 mm and greaterthan 50 percent of the cells have been opened by mechanical meansmeasured according to ASTM D2856, Procedure C.
 44. A process accordingto claim 1, wherein the cellular thermoplastic polymer foam structurehas been grafted with a vinyl functional silane or an azido functionalsilane.
 45. A process according to claim 44 further comprisingcrosslinking the cellular thermoplastic polymer foam structure.